ATP 106001 no longer comes with metal EGR cert sleeve

[02LTD2.0]

That is a lot of parts replacement at one time. Perhaps you should consider spreading it out over at least two or three sessions to minimize errors.

 

[02LTD2.0]

Are you having shifting issues or just doing the shift kit as preventative maintenance?

 

[RD_Atlanta]

2000LTD, thanks for alerting us to the design change.
02LTD2.0, Thanks for letting us know about the ones on Ebay. I just ordered two.

 

[2000ltd]

Are you having shifting issues or just doing the shift kit as preventative maintenance?

Preventative maintenance

 

[2000ltd]

That is a lot of parts replacement at one time. Perhaps you should consider spreading it out over at least two or three sessions to minimize errors.

I'm doing the radiator first, then driving it out to the garage. Then I'm doing the tensioner water pump intakes and valve covers. The trans ill probably do later since I may not have time or energy to do it all.

 

[02LTD2.0]

That sounds like a better plan.

When you do the tranny work make sure that you re-use the factory pan gasket and NOT the paper gasket that comes with the filter.

 

[2000ltd]

That sounds like a better plan.

When you do the tranny work make sure that you re-use the factory pan gasket and NOT the paper gasket that comes with the filter.

Ok I will.

 

[2000ltd]

Ok I will.

Is there a tightening sequence on the trans pan and what is the torque specs for those bolts for the pan

 

[02LTD2.0]

Not sure of the torque specs but it's not a lot and you would go in a cross cross pattern. I'm sure someone else will come up with the exact specifics.

 

[2000ltd]

I got my old stock ATP greywerks manifold today from eBay. It has the metal-cert sleeve and is what I was looking for in a manifold replacement. In the photo below the two black round holes on each manifold are different between the old and the new manifold. The old one with the metal sleeve is on the left and the new one they make now has smaller holes and no metal sleeve is on the right.

 

[RD_Atlanta]

I got my old stock ATP greywerks manifold today from eBay. It has the metal-cert sleeve and is what I was looking for in a manifold replacement. In the photo below the two black round holes on each manifold are different between the old and the new manifold. The old one with the metal sleeve is on the left and the new one they make now has smaller holes and no metal sleeve is on the right.

Thanks for sharing. Any ideas as to why they think this change would help?

 

[2000ltd]

Thanks for sharing. Any ideas as to why they think this change would help?

I think those holes are for coolant passage. The large hole in the middle that used to have a metal sleeve is for the EGR chimney and apparently what used to happen is it would melt or deform in that area allowing the coolant to leak. I think maybe they are increasing the distance of the coolant from the hot EGR port and therefore may not need the metal sleeve anymore.

 

[2003LesabreDriver]

I also bought this same ATP intake plenum from RA this past April. Its missing the steel insert also and the whole plenum is made of a different beefier material. I've done three of these 3800 upper and lower intake repairs over the past few years. The thing I hate most is the plenum gasket does not say aligned to the 6 inner intake tubes. I had to warm up a couple of the tubes to allow me to flex them to stay aligned to the gasket. I would hate for the gasket or carrier frame to break when torquing it down to the lower intake manifold. I'm guessing that would cause some severe issues.

 

[2000ltd]

I also bought this same ATP intake plenum from RA this past April. Its missing the steel insert also and the whole plenum is made of a different beefier material. I've done three of these 3800 upper and lower intake repairs over the past few years. The thing I hate most is the plenum gasket does not say aligned to the 6 inner intake tubes. I had to warm up a couple of the tubes to allow me to flex them to stay aligned to the gasket. I would hate for the gasket or carrier frame to break when torquing it down to the lower intake manifold. I'm guessing that would cause some severe issues.

What kind of problems other that that misalignment did you run into? I'm about to do this uim lim in december

 

[RD_Atlanta]

I've attempted a 'hopeful' improvement for the 3.8L Plenum EGR passage. Please view the attached image. These ceramic sleeves are available on Amazon. Link
Its a loose fit in the bore but it works out to where the can't leave the bore (the injection molding stops it on the top side and the silicon gasket stops it on the bottom side.. I glued/sealed the sleeve in the bore with high temperature Red Gasket Maker rated for 600 deg F. Link . I have several of these to do, please let me know if anyone can think of a glue or sealer that might work better. I'm 'thinking' the ceramic will be effective at reducing the temperature that reaches the plastic plenum.

 

[2000ltd]

I've attempted a 'hopeful' improvement for the 3.8L Plenum EGR passage. Please view the attached image. These ceramic sleeves are available on Amazon. Link
Its a loose fit in the bore but it works out to where the can't leave the bore (the injection molding stops it on the top side and the silicon gasket stops it on the bottom side.. I glued/sealed the sleeve in the bore with high temperature Red Gasket Maker rated for 600 deg F. Link . I have several of these to do, please let me know if anyone can think of a glue or sealer that might work better. I'm 'thinking' the ceramic will be effective at reducing the temperature that reaches the plastic plenum.

View attachment 49592

I wish I'd known this trick a few weeks ago. I had to hunt down a plenum with the metal sleeve because they stopped making them. I had to buy one on eBay that still had the old design with the metal in there. Imo the ceramic would work better to insulate and that rtv should hold it fine.

 

[2003LesabreDriver]

On my 2000 Lesabre theres a dealer service decal. It looks like GM dealers added an coolant sealant to help the known lower intake issue. You can see the sealant or crud in the photos.

I added a few pics. One shows the new EGR stovepipe that leaves a bigger gap to avoid melting the plastic plenum. I have two plenums from Rockauto. One came with the inner tube and one did not. I have two Lesabres and this is the first one that I'm doing the gasket fix to.

Also added a couple of pics with two of the ports of the original gasket showing signs of failing.

Another pic showing that I added a washer to the fasteners of the plenum to the lower intake. I think that helps to avoid point loading the plastic and breaking it. Just follow the instructions on the torque sequence and do not over torque them.

I put the new aluminum coolant elbows in. I noticed theres extra flash from on the aluminum that need to be filed flush other wise you can feel that tube rub against the mating hole. Once filled off I used grease on the o-rings to make them slid in easy and fit. You dont want to roll or pinch the o-rings.

Theres a bracket that attaches to the throttle body to the LIM. I removed the nut and unscrewed the stud in the throttle body to make it easier to remove the plenum when all the fasteners are loose. I didnt install the throttle body to the new plenum and it was a pain to deal with. So I would suggest to first install the throttle body to the plenum and then install that assembly to the LIM.

Since I also replaced both valve cover gaskets I removed the altenator and also the coolant braket with the elbows. Its just a few more bolts to remove that are easy to access. With the altenator removed it makes accessing the rear valve cover easier. Also with the coolant bracket removed you dont have to screw around aligning the elbow into the LIM during reinstallation. To remove the rear valve cover theres a bracket on the back of the engine to loosen which also helps, 2 nuts to loosen, dont remove.

There are a ton of YT videos which show this repair.

Overall its not too difficult of a job.

 

[RD_Atlanta]

On my 2000 Lesabre theres a dealer service decal. It looks like GM dealers added an coolant sealant to help the known lower intake issue. You can see the sealant or crud in the photos.

I added a few pics. One shows the new EGR stovepipe that leaves a bigger gap to avoid melting the plastic plenum. I have two plenums from Rockauto. One came with the inner tube and one did not. I have two Lesabres and this is the first one that I'm doing the gasket fix to.

Also added a couple of pics with two of the ports of the original gasket showing signs of failing.

Another pic showing that I added a washer to the fasteners of the plenum to the lower intake. I think that helps to avoid point loading the plastic and breaking it. Just follow the instructions on the torque sequence and do not over torque them.

I put the new aluminum coolant elbows in. I noticed theres extra flash from on the aluminum that need to be filed flush other wise you can feel that tube rub against the mating hole. Once filled off I used grease on the o-rings to make them slid in easy and fit. You dont want to roll or pinch the o-rings.

Theres a bracket that attaches to the throttle body to the LIM. I removed the nut and unscrewed the stud in the throttle body to make it easier to remove the plenum when all the fasteners are loose. I didnt install the throttle body to the new plenum and it was a pain to deal with. So I would suggest to first install the throttle body to the plenum and then install that assembly to the LIM.

Since I also replaced both valve cover gaskets I removed the altenator and also the coolant braket with the elbows. Its just a few more bolts to remove that are easy to access. With the altenator removed it makes accessing the rear valve cover easier. Also with the coolant bracket removed you dont have to screw around aligning the elbow into the LIM during reinstallation. To remove the rear valve cover theres a bracket on the back of the engine to loosen which also helps, 2 nuts to loosen, dont remove.

There are a ton of YT videos which show this repair.

Overall its not too difficult of a job.

xcellent write up.

On my 2000 Lesabre theres a dealer service decal. It looks like GM dealers added an coolant sealant to help the known lower intake issue. You can see the sealant or crud in the photos.

I added a few pics. One shows the new EGR stovepipe that leaves a bigger gap to avoid melting the plastic plenum. I have two plenums from Rockauto. One came with the inner tube and one did not. I have two Lesabres and this is the first one that I'm doing the gasket fix to.

Also added a couple of pics with two of the ports of the original gasket showing signs of failing.

Another pic showing that I added a washer to the fasteners of the plenum to the lower intake. I think that helps to avoid point loading the plastic and breaking it. Just follow the instructions on the torque sequence and do not over torque them.

I put the new aluminum coolant elbows in. I noticed theres extra flash from on the aluminum that need to be filed flush other wise you can feel that tube rub against the mating hole. Once filled off I used grease on the o-rings to make them slid in easy and fit. You dont want to roll or pinch the o-rings.

Theres a bracket that attaches to the throttle body to the LIM. I removed the nut and unscrewed the stud in the throttle body to make it easier to remove the plenum when all the fasteners are loose. I didnt install the throttle body to the new plenum and it was a pain to deal with. So I would suggest to first install the throttle body to the plenum and then install that assembly to the LIM.

Since I also replaced both valve cover gaskets I removed the altenator and also the coolant braket with the elbows. Its just a few more bolts to remove that are easy to access. With the altenator removed it makes accessing the rear valve cover easier. Also with the coolant bracket removed you dont have to screw around aligning the elbow into the LIM during reinstallation. To remove the rear valve cover theres a bracket on the back of the engine to loosen which also helps, 2 nuts to loosen, dont remove.

There are a ton of YT videos which show this repair.

Overall its not too difficult of a job.

Excellent write-up.

 

[HotZ28]

On my 2000 Lesabre theres a dealer service decal. It looks like GM dealers added an coolant sealant to help the known lower intake issue. You can see the sealant or crud in the photos.

I added a few pics. One shows the new EGR stovepipe that leaves a bigger gap to avoid melting the plastic plenum. I have two plenums from Rockauto. One came with the inner tube and one did not. I have two Lesabres and this is the first one that I'm doing the gasket fix to.

Also added a couple of pics with two of the ports of the original gasket showing signs of failing.

Another pic showing that I added a washer to the fasteners of the plenum to the lower intake. I think that helps to avoid point loading the plastic and breaking it. Just follow the instructions on the torque sequence and do not over torque them.

I put the new aluminum coolant elbows in. I noticed theres extra flash from on the aluminum that need to be filed flush other wise you can feel that tube rub against the mating hole. Once filled off I used grease on the o-rings to make them slid in easy and fit. You dont want to roll or pinch the o-rings.

Theres a bracket that attaches to the throttle body to the LIM. I removed the nut and unscrewed the stud in the throttle body to make it easier to remove the plenum when all the fasteners are loose. I didnt install the throttle body to the new plenum and it was a pain to deal with. So I would suggest to first install the throttle body to the plenum and then install that assembly to the LIM.

Since I also replaced both valve cover gaskets I removed the altenator and also the coolant braket with the elbows. Its just a few more bolts to remove that are easy to access. With the altenator removed it makes accessing the rear valve cover easier. Also with the coolant bracket removed you dont have to screw around aligning the elbow into the LIM during reinstallation. To remove the rear valve cover theres a bracket on the back of the engine to loosen which also helps, 2 nuts to loosen, dont remove.

There are a ton of YT videos which show this repair.

Overall its not too difficult of a job.

Nice information for the ones who have never been through this whole process!

 

[2000ltd]

On my 2000 Lesabre theres a dealer service decal. It looks like GM dealers added an coolant sealant to help the known lower intake issue. You can see the sealant or crud in the photos.

I added a few pics. One shows the new EGR stovepipe that leaves a bigger gap to avoid melting the plastic plenum. I have two plenums from Rockauto. One came with the inner tube and one did not. I have two Lesabres and this is the first one that I'm doing the gasket fix to.

Also added a couple of pics with two of the ports of the original gasket showing signs of failing.

Another pic showing that I added a washer to the fasteners of the plenum to the lower intake. I think that helps to avoid point loading the plastic and breaking it. Just follow the instructions on the torque sequence and do not over torque them.

I put the new aluminum coolant elbows in. I noticed theres extra flash from on the aluminum that need to be filed flush other wise you can feel that tube rub against the mating hole. Once filled off I used grease on the o-rings to make them slid in easy and fit. You dont want to roll or pinch the o-rings.

Theres a bracket that attaches to the throttle body to the LIM. I removed the nut and unscrewed the stud in the throttle body to make it easier to remove the plenum when all the fasteners are loose. I didnt install the throttle body to the new plenum and it was a pain to deal with. So I would suggest to first install the throttle body to the plenum and then install that assembly to the LIM.

Since I also replaced both valve cover gaskets I removed the altenator and also the coolant braket with the elbows. Its just a few more bolts to remove that are easy to access. With the altenator removed it makes accessing the rear valve cover easier. Also with the coolant bracket removed you dont have to screw around aligning the elbow into the LIM during reinstallation. To remove the rear valve cover theres a bracket on the back of the engine to loosen which also helps, 2 nuts to loosen, dont remove.

There are a ton of YT videos which show this repair.

Overall its not too difficult of a job.

Did the torque value change at all with the addition of washers on the upper intake bolts? What size washers are those?